Projectile trap and shooting range

ABSTRACT

A shooting range including a shooting station positioned at one end of a firing lane. A projectile trap is disposed at an opposite end of the firing lane for collecting projectiles fired from the shooting station. The projectile trap comprises a deceleration chamber defined by a first scroll wall and a second scroll wall for dissipating kinetic energy of the projectiles and a funneling portion for directing projectiles into the deceleration chamber. The first scroll wall is curved and has a concave surface. The first scroll wall is positioned so that the concave surface of the first scroll wall generally faces in a direction towards the shooting station. The first scroll wall comprises a steel body substrate and has an enhanced impact resistant portion. The enhanced impact resistant portion has an impact resistant layer comprising a plurality of ceramic particles and a binding material bound to a forward facing surface of the steel body substrate.

This application claims priority to U.S. Provisional Application No.62/255,752 filed on Nov. 16, 2015. Said application is incorporatedherein by reference in its entirety.

FIELD OF THE TECHNOLOGY

The present disclosure relates generally to shooting ranges and, moreparticularly, to shooting ranges including projectile traps.

BACKGROUND

In order to maintain their proficiency with various types of firearms,military personnel, law enforcement officers and others routinely engagein target practice. For many years, target practice was conducted inenvironments in which there was little concern for recovering thebullets. Firing ranges commonly used a large mound of dirt to deceleratethe bullet after it had passed through the target. Such a system wasgenerally safe, in that the dirt was effective in stopping the bulletand preventing injuries.

More recently, considerable concern has been raised about the leadcontained in the bullet. Though the bullet fired into the mound of dirtwas safely contained from the point of being a moving projectile with asignificant amount of inertial momentum, the lead in the bullet was freeto escape into the environment. For example, when a mound containing anumber of bullets became wet, lead could leach into surrounding soil andeven the groundwater. When a range was used frequently a considerableamount of lead could be released into the environment, thereby injuringwildlife and contaminating groundwater supplies.

One type of shooting range introduced by the Applicant includesprojectile traps configured as deceleration trap chamber units. Thesedeceleration trap chamber units are often characterized as snailchambers in that in they have a bullet entry funnel opening toward ashooting station with the funnel at the top of a substantiallycylindrical chamber, resembling the cross section of a snail shell. Thebullet can enter the substantially cylindrical chamber from the funneland travel somewhat circularly around the inner periphery of thecircular chamber until the bullet loses energy. A slot in the bottom ofthe chamber allows bullets and fragments to fall into a bin below thechamber. The bullets collected in the bin may be recycled or otherwisedisposed of in accordance with environmental regulations, therebysignificantly reducing the risks of lead escaping into the environment.Moreover, such shooting ranges may be “wet” with circulating fluid thatcaptures lead dust that could otherwise be air borne.

SUMMARY

In accordance with the present disclosure, devices and assemblies areprovided for shooting ranges. Recognizing the hazards of lead bullets,manufacturers and users, such as the military, are opting for lead freeor reduced lead bullets. The inventor has recognized that such bulletsmay have components that are not as malleable or soft as lead, or thathave a reduced tendency to fragment. Such conditions are believed tocause increased wear to conventional bullet trap deceleration chamberunits. This disclosure provides improved shooting ranges and projectiletraps that have enhanced durability and life expectancy, particularlywhen used to decelerate projectiles in trap chambers.

One embodiment of the present disclosure includes a shooting rangeincluding a shooting station positioned at one end of a firing lane. Aprojectile trap is disposed at an opposite end of the firing lane forcollecting projectiles fired from the shooting station. The projectiletrap comprises a deceleration chamber defined by a first scroll wall anda second scroll wall for dissipating kinetic energy of the projectilesand a funneling portion for directing projectiles into the decelerationchamber. The first scroll wall is curved and has a concave surface. Thefirst scroll wall is positioned so that the concave surface of the firstscroll wall generally faces in a direction towards the shooting station.The first scroll wall comprises a steel body substrate and has anenhanced impact resistant portion. The enhanced impact resistant portionhas an impact resistant layer comprising a plurality of ceramicparticles and a binding material bound to a forward facing surface ofthe steel body substrate. The second scroll wall is curved and has aconcave surface. The second scroll wall is positioned so that theconcave surface of the second scroll wall generally faces in a directionaway from the shooting station. The concave surface of the first scrollwall and the concave surface of the second scroll wall cooperate todefine the deceleration chamber. The first scroll wall and the secondscroll wall are positioned with respect to each other to define anentrance slot to the deceleration chamber. The entrance slot ispositioned to allow projectiles fired from the shooting station to enterthe deceleration chamber. The first scroll wall and the second scrollwall are also positioned with respect to each other to define an exitslot from the deceleration chamber. The exit slot is positioned so thatgravity causes material from de-energized projectiles to exit thedeceleration chamber via the exit slot.

The funneling portion of the projectile trap comprises an upper steelplate and a lower steel plate disposed on opposite sides of a horizontalplane to define an entry channel. The upper steel plate is oriented at afirst acute angle relative to the horizontal plane and the lower steelplate is oriented at a second acute angle relative to the horizontalplane so that projectiles striking one or both of the steel plates aredirected through the entrance slot of the deceleration chamber. Thefunnel portion is generally funnel shaped so that the cross sectionalarea of the entry channel decreases in a direction of projectile travel.The enhanced impact resistant portion is positioned so that projectilesdirected through the entrance slot of the deceleration chamber by theupper steel plate and the lower steel plate strike the enhanced impactresistant layer after passing through the entrance slot. For thispurpose, the enhanced impact resistant portion may he positionedproximate the entrance slot of the deceleration chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will be better understood by a reading ofthe Description of Embodiments along with a review of the drawings, inwhich:

FIG. 1 is a simplified isometric view showing an illustrative embodimentof a shooting range;

FIG. 2 is an enlarged isometric view showing a portion of the projectiletrap shown in FIG. 1;

FIG. 3 is a side view further illustrating the projectile trap shown inFIG. 2;

FIG. 4A is an enlarged side view further illustrating the first scrollwall and the second scroll wall shown in FIG. 3. FIG. 4B is an enlargedcross-sectional view further illustrating a portion of the first scrollwall shown in FIG. 4A; and

FIG. 5A through FIG. 5D are a series of stylized perspective viewsillustrating example methods in accordance with this detaileddescription and apparatus associated with those methods.

DESCRIPTION OF THE EMBODIMENTS

In the following description, like reference characters designate likeor corresponding parts throughout the several views. Also in thefollowing description, it is to be understood that such terms as“forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” andthe like are words of convenience and are not to be construed aslimiting terms.

Referring now to the drawings in general and FIG. 1 in particular, itwill be understood that the illustrations are for the purpose ofdescribing a preferred embodiment of the invention and are not intendedto limit the invention thereto. FIG. 1 is a simplified isometric viewshowing an illustrative embodiment of shooting range 10 in accordancewith this detailed description. In the illustrative embodiment of FIG.1, shooting range 10 includes four firing lanes 12. In FIG. 1, fourshooting stations 14 can be seen positioned at one end of the firinglanes 12. With reference to FIG. 1, it will be appreciated that shootingstations 14 are defined by lane dividers 16. A projectile trap 100 isdisposed at an opposite end of the firing lanes for collectingprojectiles fired from the shooting stations 14.

The projectile trap 100 comprises a deceleration chamber 102 defined bya first scroll wall 104 and a second scroll wall 106 for dissipatingkinetic energy of the projectiles fired from the shooting stations. Theprojectile trap 100 also comprises a funneling portion 108 for directingprojectiles into the deceleration chamber 102. With reference to FIG. 1it will be appreciated that the first scroll wall 104 is curved and hasa concave surface. In the embodiment of FIG. 1, the first scroll wall104 is positioned so that the concave surface generally faces in adirection towards the shooting stations 14. In some useful embodiments,the first scroll wall 104 comprises a steel body substrate and has anenhanced impact resistant portion. The enhanced impact resistant portionmay have an impact resistant layer comprising a plurality of ceramicparticles and a binding material bound to a forward facing surface ofthe steel body substrate.

With reference to FIG. 1, it will be appreciated that the second scrollwall 106 is curved and has a concave surface. In the embodiment of FIG.1, the second scroll wall 106 is positioned so that this concave surfacegenerally faces in a direction away from the shooting stations 14. Theconcave surface of the first scroll wall 104 and the concave surface ofthe second scroll wall 106 cooperating to define deceleration chamber102. Shooting range 10 of FIG. 1 may be located indoors or outdoors.When shooting range 10 is located outdoors, limited access to theshooting range 10 may be provided by fencing and supplemented, in part,by projectile trap 100.

FIG. 2 is an enlarged isometric view showing a portion of the projectiletrap 100 shown in the previous figure. The projectile trap 100 comprisesa deceleration chamber 102 defined by a first scroll wall 104 and asecond scroll wall 106 for dissipating kinetic energy of the projectilesfired from the shooting stations. The projectile trap 100 also comprisesa funneling portion 108 for directing projectiles into the decelerationchamber 102.

In the embodiment of FIG. 2, the first scroll wall 104 has a concavesurface 120A and the second scroll wall 106 has a concave surface 120B.The concave surface 120A of the first scroll wall 104 and the concavesurface 120B of the second scroll wall 106 cooperate to definedeceleration chamber 102. In some useful embodiments, the first scrollwall 104 comprises a steel body substrate and has an enhanced impactresistant portion. The funneling portion 108 of the projectile trap 100comprises an upper steel plate 126 and a lower steel plate 128. Theupper steel plate 126 and the lower steel plate 128 are arranged soprojectiles striking one or both of the steel plates are directed intothe deceleration chamber 102 defined by the concave surface 120A of thefirst scroll wall 104 and the concave surface 120B of the second scrollwall 106.

FIG. 3 is a side view further illustrating the projectile trap 100 shownin the previous figure. The projectile trap 100 comprises a decelerationchamber 102 defined by a first scroll wall 104 and a second scroll wall106 for dissipating kinetic energy of the projectiles fired from theshooting stations. The projectile trap 100 also comprises a funnelingportion 108 for directing projectiles into the deceleration chamber 102.

In the embodiment of FIG. 3, the first scroll wall 104 has a concavesurface 120A and the second scroll wall 106 has a concave surface 120B.The concave surface 120A of the first scroll wall 104 and the concavesurface 120B of the second scroll wall 106 cooperate to definedeceleration chamber 102.

The first scroll wall 104 and the second scroll wall 106 are positionedwith respect to each other to define an exit slot 124 from thedeceleration chamber 102. The exit slot 124 is positioned so thatgravity causes material from de-energized projectiles to exit thedeceleration chamber 102 via the exit slot 124.

The funneling portion 108 of the projectile trap 100 comprises an uppersteel plate 126 and a lower steel plate 128 disposed on opposite sidesof a horizontal plane H to define an entry channel 130. The upper steelplate 126 is oriented at a first acute angle relative to the horizontalplane H and the lower steel plate 128 is oriented at a second acuteangle relative to the horizontal plane H so that projectiles strikingone or both of the steel plates are directed into the decelerationchamber 102. With reference to FIG. 3, it will be appreciated thatfunnel portion 108 is generally funnel shaped so that the crosssectional area of the entry channel 130 decreases in a direction ofprojectile travel PT. The direction of projectile travel PT isillustrated with an arrow in FIG. 3.

The first scroll wall 104 and the second scroll wall 106 are positionedwith respect to each other to define an entrance slot 122 to thedeceleration chamber 102. The entrance slot 122 is positioned to allowprojectiles passing through entry channel 130 between upper steel plate126 and lower steel plate 128 to enter the deceleration chamber 102.

In the embodiment of FIG. 3, the first scroll wall 104 comprises a steelbody substrate and has an enhanced impact resistant portion 132. Theenhanced impact resistant portion 132 is positioned so that projectilesdirected through the entrance slot 122 of the deceleration chamber 102by the upper steel plate 126 and the lower steel plate 128 strike theenhanced impact resistant portion 132 after passing through the entranceslot 122. With reference to FIG. 3, it will be appreciated that theenhanced impact resistant portion 132 is positioned proximate theentrance slot 122 of the deceleration chamber 102.

FIG. 4A is an enlarged side view further illustrating the first scrollwall 104 and the second scroll wall 106 shown in the previous figure.FIG. 4B is an enlarged cross-sectional view further illustrating aportion of first scroll wall 104. FIG. 4A and FIG. 4B may becollectively referred to as FIG. 4.

In the embodiment of FIG. 4, the first scroll wall 104 has a concavesurface 120A and the second scroll wall 106 has a concave surface 120B.The concave surface 120A of the first scroll wall 104 and the concavesurface 120B of the second scroll wall 106 cooperate to define adeceleration chamber 102. The first scroll wall 104 and the secondscroll wall 106 are also positioned with respect to each other to definean entrance slot 122 to the deceleration chamber 102. The entrance slot122 is positioned to allow projectiles to enter the deceleration chamber102.

In some useful embodiments, the first scroll wall 104 comprises a steelbody substrate 140 and has an enhanced impact resistant portion 132. Thefirst metal alloy may comprise, for example, AR500 steel. The enhancedimpact resistant portion 132 is positioned so that projectiles directedthrough the entrance slot 122 of the deceleration chamber 102 strike theenhanced impact resistant portion 132 after passing through the entranceslot 122. With reference to FIG. 4, it will be appreciated that theenhanced impact resistant portion 132 is positioned proximate theentrance slot 122 of the deceleration chamber 102.

The enhanced impact resistant portion 132 has an impact resistant layer134 comprising a plurality of ceramic particles 136 and a bindingmaterial 138 bound to a forward facing surface of the steel bodysubstrate 140. In the embodiment of FIG. 4, the ceramic particles 136 ofthe impact resistant layer 134 are bound to the steel body substrate 140by the binding material 138. In some useful embodiments, the ceramicparticles comprise a material selected from the group consisting ofaluminum oxide, boron carbide, boron nitride, silicon carbide, siliconnitride, and zirconium oxide.

In some useful embodiments, the steel body substrate 140 comprises afirst metal alloy and the binding material 138 comprises a second metalalloy different from the first metal alloy. When this is the case, thefirst metal alloy and the second metal ahoy may both comprise chromium.In some useful embodiments, the first metal alloy and the second metalalloy both comprise nickel. The second metal alloy may comprise cobaltin some useful embodiments.

With reference to FIG. 4, it will be appreciated that the impactresistant layer 134 has a thickness T that is greater than an averagedimension of the ceramic particles 136. The impact resistant layer 134may be formed using a thermal spraying process. Examples of thermalspraying processes that may be suitable in some applications include:flame spraying processes, high velocity oxy-fuel (HVOF) sprayingprocesses, and plasma spraying process.

FIG. 5A through FIG. 5D are a series of stylized perspective viewsillustrating example methods in accordance with this detaileddescription and apparatus associated with those methods. FIG. 5A throughFIG. 5D may be collectively referred to as FIG. x.

At FIG. 5A, the first scroll wall is cut to a desired size from a supplyof sheet metal stock. In some useful embodiments, the first scroll wallcomprises AR500 steel. At FIG. 5B, a bending process is used to give thefirst scroll wall a curved shape.

At FIG. 5C, a thermal coating process is used to apply an impactresistant layer 134 to a steel body substrate of the first scroll wall.Examples of thermal spraying processes that may be suitable in someapplications include: flame spraying processes, high-velocity oxy-fuel(HVOF) spraying processes, and plasma spraying process.

At FIG. 5D, a strongback is attached to the first scroll wall. In theembodiment of FIG. 5D, the strongback includes two flanges and aplurality of stringers formed from C channel. Various processes may beused to attach the strongback to the first scroll wall. In someapplications, the strongback is welded to the first scroll wall.

With reference to FIG. 5, it will be appreciated that a method offabricating a scroll wall for a bullet trap my include providing a sheetof material and cutting a flat steel plate from the sheet of material.The flat steel plate may be bent to create a scroll wall having adesired curvature. A strongback may be attached to the scroll wall, forexample, by welding. A plurality of ceramic particles and a bindingmaterial may be deposited onto a concave surface of the scroll wall toform an impact resistant layer. Methods in accordance with this detaileddescription may also include the cleaning the concave surface of thescroll wall and heat treating the scroll wall.

In some embodiments, depositing the plurality of ceramic particles andthe binding material onto the concave surface of the scroll wall to formthe impact resistant layer may comprise creating a plasma plume bypassing a flow of gas through an electric arc, directing the plasmaplume toward the concave surface of the scroll wall. A plurality ofceramic particles and a binding material may be injected into the flowof gas so that the ceramic particles and the binding material passthrough the plasma plume. Heat from the plasma plume may cause thebinding material to become molten binding material. The ceramicparticles and the molten binding material may be deposited onto theconcave surface of the scroll wall to form an impact resistant layer. Insome useful embodiments, the ceramic particles comprise a materialselected from the group consisting of aluminum oxide, boron carbide,boron nitride, silicon carbide, silicon nitride, and zirconium oxide.

In other embodiments, depositing the plurality of ceramic particles andthe binding material onto the concave surface of the scroll wall to formthe impact resistant layer may comprise providing a flow of gasesincluding a fuel gas and oxygen and igniting the flow of gases create aflame. The ceramic particles and the binding material may be injectedinto the flow of gases so that the ceramic particles and the bindingmaterial pass through the flame. Heat from the flame may cause thebinding material to become molten binding material. The ceramicparticles and the molten binding material may be deposited onto theconcave surface of the scroll wall to form an impact resistant layer.

It is also contemplated that methods in accordance with this detaileddescription may be used for maintaining or repairing an existing firingrange having a shooting station positioned at one end of a firing laneand a projectile trap disposed at an opposite end of the firing lane forcollecting projectiles fired from the shooting station, the projectingtrap comprising a scroll wall at least partially defining a decelerationchamber. When this is the case, a plurality of ceramic particles and abinding material may be deposited onto a concave surface of the scrollwall to form an impact resistant layer. The impact resistant layer maybe applied to the concave surface of the scroll wall while the scrollwall is attached to the bullet trap. When this is the case, the scrollwall does not need to be removed from the bullet trap. Alternately, themethod could include detaching the scroll wall from the bullet trap.Detaching the scroll wall from the bullet trap may comprise removing aplurality of fasteners. This maintenance or repair may be performed on“wet” bullet traps which include a circulating fluid that captures leaddust that could otherwise be air borne. When this is the case, acleaning process may be used to remove lubricant residue which may beleft by the circulating fluid from the concave surface of the scrollwall.

Certain modifications and improvements may occur to those skilled in theart upon a reading of the foregoing description. By way of example,while the shooting range shown includes a circular projectiledeceleration trap chamber, other types of traps could be used,including, without limitation, the kind having an impact plate design.It should also be apparent that any rounded shape could be used as aprojectile trap and the invention is not limited to just circular onesided shapes. Also, the deceleration trap chamber could be made from aseries of plates having flat faces, such as shown in U.S. Pat. No.5,811,718, issued to Bateman. All such modifications and improvementshave not been included herein for the sake of conciseness andreadability but may properly fall within the scope of the appendedclaims. Patents incorporated by reference herein for all purposes: U.S.Pat. No. 7,434,811; U.S. Pat. No. 5,486,008; U.S. Pat. No. 5,113,700;and U.S. Pat. No. 8,459,651.

Numerous characteristics and advantages have been set forth in theforegoing description, together with details of structure and function.Many of the novel features 5 are pointed out in the appended examplesand claims. The disclosure, however, is illustrative only, and changesmay be made in detail, especially in matters of shape, size, andarrangement of parts, within the principle of the disclosure, to thefull extent indicated by the broad general meaning of the terms in whichthe general claims are expressed. It is further noted that, as used inthis application, the singular forms “a,” “an,” and “the” include pluralreferents unless expressly and unequivocally limited to one referent.

We claim:
 1. A shooting range, comprising: a shooting station positionedat one end of a firing lane; a projectile trap disposed at an oppositeend of the firing lane for collecting projectiles fired from theshooting station; the projectile trap comprising a deceleration chamberdefined by a first scroll wall and a second scroll wall for dissipatingkinetic energy of the projectiles and a funneling portion for directingprojectiles into the deceleration chamber; the first scroll wall beingcurved and having a concave surface, the first scroll wall beingpositioned so that the concave surface of the first scroll wallgenerally faces in a direction towards the shooting station, the firstscroll wall comprising a steel body substrate and having an enhancedimpact resistant portion, the enhanced impact resistant portion havingan impact resistant layer comprising a plurality of ceramic particlesand a binding material bound to a forward facing surface of the steelbody substrate; the second scroll wall being curved and having a concavesurface, the second scroll wall being positioned so that the concavesurface of the second scroll wall generally faces in a direction awayfrom the shooting station; the concave surface of the first scroll walland the concave surface of the second scroll wall cooperating to definethe deceleration chamber; the first scroll wall and the second scrollwall positioned with respect to each other to define an entrance slot tothe deceleration chamber, the entrance slot being positioned to allowprojectiles fired from the shooting station to enter the decelerationchamber; the first scroll wall and the second scroll wall furtherpositioned with respect to each other to define an exit slot from thedeceleration chamber, the exit slot being positioned so that gravitycauses material from de-energized projectiles to exit the decelerationchamber via the exit slot; the funneling portion of the projectile trapcomprising an upper steel plate and a lower steel plate disposed onopposite sides of a horizontal plane to define an entry channel; theupper steel plate being oriented at a first acute angle relative to thehorizontal plane and the lower steel plate being oriented at a secondacute angle relative to the horizontal plane so that projectilesstriking one or both of the steel plates are directed through theentrance slot of the deceleration chamber, wherein a Cross sectionalarea of the entry channel decreases in a direction of projectile travel;wherein the enhanced impact resistant portion is positioned proximatethe entrance slot of the deceleration chamber; and wherein projectilesdirected through the entrance slot of the deceleration chamber by theupper steel plate and the lower steel plate strike the enhanced impactresistant layer.
 2. The shooting range of claim 1, wherein the particlescomprise a material selected from the group consisting of aluminumoxide, boron carbide, boron nitride, silicon carbide, silicon nitride,and zirconium oxide.
 3. The shooting range of claim 1, wherein theparticles of the impact resistant layer are bound to the steel bodysubstrate by the binding material.
 4. The shooting range of claim 1,wherein: the steel body substrate comprises a first metal alloy; and thebinding material comprises a second metal alloy different from the firstmetal alloy.
 5. The shooting range of claim 4, wherein the first metalalloy comprises AR500 steel.
 6. The shooting range of claim 4, whereinthe first metal alloy and the second metal alloy both comprise chromium.7. The shooting range of claim 4, wherein the first metal alloy and thesecond metal alloy both comprise nickel.
 8. The shooting range of claim1, wherein the thermal spraying process comprises a flame sprayingprocess.
 9. The shooting range of claim 8, wherein the thermal sprayingprocess comprises a high velocity oxy-fuel spraying process.
 10. Theshooting range of claim 8, wherein the thermal spraying processcomprises a plasma spraying process.
 11. A method for maintaining orrepairing an existing firing range having a shooting station positionedat one end of a firing lane and a projectile trap disposed at anopposite end of the firing lane for collecting projectiles fired fromthe shooting station, the projecting trap comprising a scroll wall atleast partially defining a deceleration chamber, the method comprisingdepositing a plurality of ceramic particles and a binding material ontoa concave surface of the scroll wall to form an impact resistant layer.12. The method of claim 11, wherein impact resistant layer is applied tothe concave surface of the scroll wall while the scroll wall is attachedto the bullet trap.
 13. The method of claim 11, wherein depositing theplurality of ceramic particles and the binding material onto the concavesurface of the scroll wall to form the impact resistant layer,comprises: providing a plurality of ceramic particles and a bindingmaterial; creating a plasma plume by passing a flow of gas through anelectric arc; directing the plasma plume toward the concave surface ofthe scroll wall; injecting the ceramic particles and the bindingmaterial into the flow of gas so that the ceramic particles and thebinding material pass through the plasma plume, wherein heat from theplasma plume causes the binding material to become molten bindingmaterial; and depositing the ceramic particles and the molten bindingmaterial onto the concave surface of the scroll wall to form an impactresistant layer.
 14. The method of claim 11, depositing the plurality ofceramic particles and the binding material onto the concave surface ofthe scroll wall to form the impact resistant layer, comprises: providinga plurality of ceramic particles and a binding material; providing aflow of gases including a fuel gas and oxygen; igniting the flow ofgases create a flame; directing the flow of gases toward the concavesurface of the scroll wall; injecting the ceramic particles and thebinding material into the flow of gases so that the ceramic particlesand the binding material pass through the flame, wherein heat from theflame causes the binding material to become molten binding material; anddepositing the ceramic particles and the molten binding material ontothe concave surface of the scroll wall to form an impact resistantlayer.
 15. The method of claim 11, wherein the ceramic particlescomprise a material selected from the group consisting of aluminumoxide, boron carbide, boron nitride, silicon carbide, silicon nitride,and zirconium oxide.
 16. The method of claim 11, wherein the ceramicparticles become bound to the substrate layer by the binding material.17. A method of fabricating a scroll wall for a bullet trap, the methodcomprising: providing a sheet of material; cutting a flat steel platefrom the sheet of material; bending the flat steel plate to create ascroll wall having a desired curvature; attaching a strongback to thescroll wall; and depositing a plurality of ceramic particles and abinding material onto a concave surface of the scroll wall to form animpact resistant layer.
 18. The method of claim 17, wherein depositingthe plurality of ceramic particles and the binding material onto theconcave surface of the scroll wall to form the impact resistant layer,comprises:. providing a plurality of ceramic particles and a bindingmaterial; creating a plasma plume by passing a flow of gas through anelectric arc; directing the plasma plume toward the concave surface ofthe scroll wall; injecting the ceramic particles and the bindingmaterial into the flow of gas so that the ceramic particles and thebinding material pass through the plasma plume, wherein heat from theplasma plume causes the binding material to become molten bindingmaterial; and depositing the ceramic particles and the molten bindingmaterial onto the concave surface of the scroll wall to form an impactresistant layer.
 19. The method of claim 17, depositing the plurality ofceramic particles and the binding material onto the concave surface ofthe scroll wall to form the impact resistant layer, comprises: providinga plurality of ceramic particles and a binding material; providing aflow of gases including a fuel gas and oxygen; igniting the flow ofgases create a flame; directing the flow of gases toward the concavesurface of the scroll wall; injecting the ceramic particles and thebinding material into the flow of gases so that the ceramic particlesand the binding material pass through the flame, wherein heat from theflame causes the binding material to become molten binding material; anddepositing the ceramic particles and the molten binding material ontothe concave surface of the scroll wall to form an impact resistantlayer.
 20. The method of claim 18, wherein the ceramic particlescomprise a material selected from the group consisting of aluminumoxide, boron carbide, boron nitride, silicon carbide, silicon nitride,and zirconium oxide.